Method of making prefastened refastenable disposable absorbent articles

ABSTRACT

The present disclosure relates to methods for manufacturing absorbent articles, and in particular, methods for making pre-fastened refastenable pant diapers. Aspects of the methods according to the present disclosure relate to the fabrication of refastenable pant diapers wherein discrete chassis are advanced in a machine direction such that the lateral axis is parallel with the machine direction. First side panels are then refastenably connected with the first waist region, and second side panels are permanently connected the second waist regions of the discrete chassis. The chassis are connected with discrete lengths of side panel material and/or connection zone material. The chassis are then folded, and the first and second side panels are subsequently bonded together. The article is then subjected to knife cut at or adjacent the bonded regions to create discrete, pre-fastened refastenable pant diapers.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/382,590, filed on Sep. 14, 2010, which is incorporated herein byreference.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to methods for making pre-fastenedrefastenable disposable absorbent articles.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from advancing web or webs are combinedwith other individual components created from other advancing web orwebs. Webs of material and component parts used to manufacture diapersmay include: backsheets, topsheets, leg cuffs, waist caps, absorbentcore components, front and/or back ears, fastening components, andvarious types of elastic webs and components such as leg elastics,barrier leg cuff elastics, stretch side panels, and waist elastics. Oncethe desired component parts are assembled, the advancing web(s) andcomponent parts are subjected to a final knife cut to separate theweb(s) into discrete diapers or other absorbent articles.

In some converting configurations, discrete chassis spaced apart fromeach other are advanced in a machine direction and are arranged with alongitudinal axis parallel with the cross direction. Opposing waistregions of discrete chasses are then connected with continuous lengthsof elastically extendable front and back belts advancing in the machinedirection. While connected with the chassis, the front and back beltsare maintained in a fully stretched condition along the machinedirection. As such, the positions of the advancing chassis andassociated belts can be controlled more easily to allow for moreaccurate registration and phasing of subsequent converting operations,such as folding, seaming, and cutting. However, introducing discreteelastically extendable components in one or both of the waist regionspresents a different challenge with regard to maintaining control andpositioning of the advancing discrete elastically extendable componentsrelative to other components, such as an article chassis, can bedifficult. For example, when manufacturing refastenable diaper pantswith a chassis connected with discrete lengths of elastically extendablepanel material disposed in one or both waist regions, some processesutilize a sheet that interconnects the discrete lengths of extendablepanel material together during manufacturing, and in turn, enhances theability to control the advancing components. The sheet is included aspart of the manufactured diapers and must be removed by the user beforeusing the refastenable features of the diapers. However, including sucha removable sheet on manufactured diaper pants may have a negativeimpact on costs and aesthetics.

SUMMARY OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and in particular, methods for making pre-fastenedrefastenable pant diapers. Aspects of the methods according to thepresent disclosure relate to the fabrication of refastenable pantdiapers wherein discrete chassis are advanced in a machine directionsuch that the lateral axis is parallel with the machine direction. Firstside panels are then refastenably connected with the first waist region,and second side panels are permanently connected the second waistregions of the discrete chassis. The chassis are connected with discretelengths of side panel material and/or connection zone material, forminga continuous web of articles formed by intermittently spaced chassis andintermittently spaced side panels bridging the gap between theintermittently spaced chassis. The chassis are then folded, and thefirst and second side panels are subsequently bonded together. Thearticle is then subjected to knife cut at or adjacent the bonded regionsto create discrete, pre-fastened refastenable pant diapers.

In one form, a process may be adapted for assembling disposablepre-fastened pant diapers, each pant diaper comprising a chassis havinga first waist region longitudinally opposed to a second waist region,and having a longitudinal axis and a lateral axis, the chassiscomprising: a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet, each pant diaper furthercomprising laterally opposed first side panels refastenably connectedwith the first waist region; and laterally opposed second side panelspermanently connected with the second waist region and permanentlyconnected with corresponding first side panels to form a waist opening.The process includes the steps of: advancing a first continuous webhaving a first surface and an opposing second surface in a machinedirection wherein fastener components are connected with the firstsurface; cutting the first continuous web into discrete patches, eachpatch having a leading end region, a trailing end region, and a centralregion disposed between the leading and trailing end regions, wherein afirst fastener is located in the leading end region and a secondfastener is located in the trailing end region; advancing a secondcontinuous web in the machine direction; advancing a third continuousweb in the machine direction; cutting the third continuous web intodiscrete chassis, wherein each chassis advances such that thelongitudinal axis is parallel with the machine direction; turning eachchassis such that the lateral axis is parallel with the machinedirection; refastenably connecting the first waist region of eachchassis with a trailing end region of a first advancing patch and with aleading end region of a second advancing patch; permanently connectingthe second waist region of each chassis with the second continuous web;folding each chassis along the lateral axis to position the centralregion of each patch into a facing relationship with the secondcontinuous web; bonding a portion of the central region each patch withthe second continuous web to create discrete bond regions; and cuttingthe second continuous web and the patches along the bond regions tocreate discrete pre-fastened refastenable pant diapers.

In another form, a process may be adapted for assembling disposablepre-fastened pant diapers, each pant diaper comprising a chassis havinga first waist region longitudinally opposed to a second waist region,and having a longitudinal axis and a lateral axis, the chassiscomprising: a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet, each pant diaper furthercomprising laterally opposed first side panels refastenably connectedwith the first waist region; and laterally opposed second side panelspermanently connected with the second waist region and permanentlyconnected with corresponding first side panels to form a waist opening.The process includes the steps of: advancing a first continuous webhaving a first surface and an opposing second surface in a machinedirection wherein fastener components are connected with the firstsurface; cutting the first continuous web into first discrete patches,each first patch having a leading end region, a trailing end region, anda central region disposed between the leading and trailing end regions,wherein a first fastener is located in the leading end region and asecond fastener is located in the trailing end region; advancing asecond continuous web in the machine direction; cutting the secondcontinuous web into second discrete patches, each second patch having aleading end region, a trailing end region, and a central region disposedbetween the leading and trailing end regions, advancing a thirdcontinuous web in the machine direction; cutting the third continuousweb into discrete chasses, wherein each chassis advances such that thelongitudinal axis is parallel with the machine direction; turning eachchassis such that the lateral axis is parallel with the machinedirection; refastenably connecting the first waist region of eachchassis with a trailing end region of an advancing first patch and witha leading end region of a subsequently advancing first patch;permanently connecting the second waist region of each chassis with atrailing end region of an advancing second patch and with a leading endregion of a subsequently advancing second patch; folding each chassisalong the lateral axis to position the central region of each firstpatch into a facing relationship with the central region of each secondpatch; bonding a portion of the central region of each first patch witha portion of each second patch to create discrete bond regions; andcutting the first and second patches along the bond regions to creatediscrete pre-fastened refastenable pant diapers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a refastenable pant diaper in apre-fastened configuration.

FIG. 2A is a partially cut away plan view of the diaper pant shown inFIG. 1.

FIG. 2B is a partially cut away plan view of a second embodiment of adiaper pant.

FIG. 3 is a schematic side view of a first converting apparatus adaptedto manufacture pre-fastened, refastenable pant diapers.

FIG. 4 is a schematic side view of a second converting apparatus adaptedto manufacture pre-fastened, refastenable pant diapers.

FIG. 5A is a view of a continuous length of chassis assemblies fromFIGS. 3 and 4 taken along line A-A.

FIG. 5B1 is a view of a discrete chassis from FIGS. 3 and 4 taken alongline B1-B1.

FIG. 5B2 is a view of a discrete chassis from FIGS. 3 and 4 taken alongline B2-B2.

FIG. 5C is a view of a continuous length of advancing back side panelmaterial from FIG. 3 taken along line C-C.

FIG. 5D is a view of a continuous length of front side panel materialfrom FIGS. 3 and 4 taken along line D-D.

FIG. 5E is a view of a discrete length of front side panel material fromFIGS. 3 and 4 taken along line E-E.

FIG. 5F1 is a view of multiple discrete chassis spaced from each otheralong the machine direction MD connected with each other by the backside panel material and discrete lengths of front side panel materialfrom FIG. 3 taken along line F1-F1.

FIG. 5F2 is a view of multiple discrete chassis spaced from each otheralong the machine direction MD connected with each other by the discretelengths of back side panel material and discrete lengths of front sidepanel material from FIG. 4 taken along line F2-F2.

FIG. 5G is a view of the back side panel material bonded with a portionof the front side panel material from FIGS. 3 and 4 taken along lineG-G.

FIG. 5H is a view of two discrete absorbent articles advancing themachine direction MD from FIGS. 3 and 4 taken along line H-H.

FIG. 5J is a view of a continuous length of advancing back side panelmaterial from FIG. 4 taken along line J-J.

FIG. 5K is a view of a discrete length of advancing back side panelmaterial from FIG. 4 taken along line K-K.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

The term “disposed” is used herein to mean that an element(s) is formed(joined and positioned) in a particular place or position as amacro-unitary structure with other elements or as a separate elementjoined to another element.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper-pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the article using any refastenable and/or permanent closuremember (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). A pant can be preformed anywherealong the circumference of the article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed). Example diaper pants in various configurations are disclosedin Japanese Patent Publication No. 1995080023A published Mar. 8, 1995.

“Pre-fastened” refers herein to pant diapers manufactured and providedto consumers in a configuration wherein the front waist region and theback waist region are fastened or connected to each other as packaged,prior to being applied to the wearer. As such pant diapers may have acontinuous perimeter waist opening and continuous perimeter leg openingsdesigned for infant or adult wearers. As discussed in more detail below,a diaper pant can be preformed by various techniques including, but notlimited to, joining together portions of the diaper using refastenableand/or permanent closure members (e.g., seams, heat bonds, pressurewelds, adhesives, cohesive bonds, mechanical fasteners, etc.). Inaddition, pant diapers can be preformed anywhere along the circumferenceof the waist region (e.g., side fastened or connected, front waistfastened or connected, rear waist fastened or connected).

The present disclosure relates to methods for manufacturing absorbentarticles, and in particular, methods for making pre-fastenedrefastenable pant diapers. As discussed in more detail below,pre-fastened pant diapers may include a chassis having a first waistregion and a longitudinally opposed second waist region. The chassis mayalso include a longitudinal axis and a lateral axis, wherein thelongitudinal axis extends through the first and second waist regions.Each pant diaper may further include laterally opposed first side panelsrefastenably connected with the first waist region, and laterallyopposed second side panels permanently connected with the second waistregion and permanently connected with corresponding first side panels toform a waist opening. Aspects of the methods according to the presentdisclosure relate to the fabrication of refastenable pant diaperswherein discrete chassis are advanced in a machine direction such thatthe lateral axis is parallel with the machine direction. The discretechassis are also spaced apart from each other along the machinedirection. First side panels are then refastenably connected with thefirst waist region, and second side panels are permanently connected thesecond waist regions of the discrete chassis. As discussed in moredetail below, the methods disclosed herein connect chassis with discretelengths of side panel material and/or connection zone material andeliminates the need for a removable sheet used in some manufacturingprocesses. This configuration forms a continuous web of articles formedby intermittently spaced chassis and intermittently spaced side panelsbridging the gap between the intermittently spaced chassis. The forcesimposed on the continuous web of absorbent articles during manufacturethereby extend through the front side panels and front waist region ofthe chassis and the back side panels and the back waist region of thechassis. The chassis are then folded in the cross direction parallel toa lateral centerline and the first and second side panels aresubsequently bonded together. The article is then subjected to knife cutat or adjacent the bonded regions to create discrete, pre-fastenedrefastenable pant diapers.

The following provides a general description of various types of pantdiapers that may be produced with the methods and apparatuses disclosedherein to help provide additional context to the subsequent discussionof the process embodiments.

FIGS. 1 and 2A show an example of a refastenable pant diaper 100 thatmay be constructed in accordance with the methods disclosed herein. Inparticular, FIG. 1 shows a perspective view of a refastenable pantdiaper 100 in a pre-fastened configuration, and FIG. 2A shows a planview of the pant diaper 100 with the portion of the diaper that facesaway from a wearer oriented towards the viewer. The pant diaper 100shown in FIGS. 1 and 2A includes a chassis 102, first front ear panels112 a, 112 b, and second back ear panels 114 a, 114 b.

With continued reference to FIG. 2A, the chassis 102 includes a firstwaist region 116, a second waist region 118, and a crotch region 120disposed intermediate the first and second waist regions. The firstwaist region 116 may be configured as a front waist region, and thesecond waist region 118 may be configured as back waist region. In someembodiments, the length of each of the front waist region, back waistregion, and crotch region may be ⅓ of the length of the absorbentarticle 100. The diaper 100 may also include a laterally extending frontwaist edge 120 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100 and chassis 102 of FIG. 2A is shown with a longitudinalaxis 124 and a lateral axis 126. In some embodiments, the longitudinalaxis 124 may extend through the front waist edge 120 and through theback waist edge 122. And the lateral axis 126 may extend through a firstlongitudinal or right side edge 128 and through a midpoint of a secondlongitudinal or left side edge 130 of the chassis 102.

As shown in FIGS. 1 and 2A, the pant diaper 100 may include an inner,body facing surface 132, and an outer, garment facing surface 134. Thechassis 102 may include a backsheet 136 and a topsheet 138. An absorbentassembly 140 including an absorbent core 142 may be disposed between aportion of the topsheet 138 and the backsheet 136. As discussed in moredetail below, the diaper 100 may also include other features, such asleg elastics and/or leg cuffs to enhance the fit around the legs of thewearer.

As shown in FIG. 2A, the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130; a first laterally extending end edge 144 disposed in the firstwaist region 116; and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the front waist edge 120 and the back waist edge122. The laterally extending end edges 144 and 146 of the chassis mayform a portion of the laterally extending front waist edge 120 in thefront waist region 116 and a portion of the longitudinally opposing andlaterally extending back waist edge 122 in the back waist region 118.When the pant diaper 100 is worn on the lower torso of a wearer, thefront waist edge 120 and the back waist edge 122 of the chassis 102 mayencircle a portion of the waist of the wearer. At the same time, thechassis side edges 128 and 130 may encircle at least a portion of thelegs of the wearer. And the crotch region 120 may be generallypositioned between the legs of the wearer with the absorbent core 142extending from the front waist region 116 through the crotch region 120to the back waist region 118.

It is to also be appreciated that a portion or the whole of the diaper100 may also be made laterally extensible. The additional extensibilitymay help allow the diaper 100 to conform to the body of a wearer duringmovement by the wearer. The additional extensibility may also help, forexample, allow the user of the diaper 100 including a chassis 102 havinga particular size before extension to extend the front waist region 116,the back waist region 118, or both waist regions of the diaper 100and/or chassis 102 to provide additional body coverage for wearers ofdiffering size, i.e., to tailor the diaper to an individual wearer. Suchextension of the waist region or regions may give the absorbent articlea generally hourglass shape, so long as the crotch region is extended toa relatively lesser degree than the waist region or regions, and mayimpart a tailored appearance to the article when it is worn.

As previously mentioned, the pant diaper 100 may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may be impervious to fluids (e.g.,menses, urine, and/or runny feces) and may be manufactured from a thinplastic film, although other flexible liquid impervious materials mayalso be used. The backsheet 136 may prevent the exudates absorbed andcontained in the absorbent core from wetting articles which contact thediaper 100, such as bedsheets, pajamas and undergarments. The backsheet136 may also comprise a woven or nonwoven material, polymeric films suchas thermoplastic films of polyethylene or polypropylene, and/or amulti-layer or composite materials comprising a film and a nonwovenmaterial (e.g., having an inner film layer and an outer nonwoven layer).The backsheet may also comprise an elastomeric film. An examplebacksheet 140 may be a polyethylene film having a thickness of fromabout 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Exemplarypolyethylene films are manufactured by Clopay Corporation of Cincinnati,Ohio, under the designation BR-120 and BR-121 and by Tredegar FilmProducts of Terre Haute, Ind., under the designation XP-39385. Thebacksheet 136 may also be embossed and/or matte-finished to provide amore clothlike appearance. Further, the backsheet 136 may permit vaporsto escape from the absorbent core (i.e., the backsheet is breathable)while still preventing exudates from passing through the backsheet 136.The size of the backsheet 136 may be dictated by the size of theabsorbent core 142 and/or particular configuration or size of the diaper100.

Also described above, the pant diaper 100 may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be compliant, soft feeling, andnon-irritating to the wearer's skin. It may be elastically stretchablein one or two directions. Further, the topsheet 138 may be liquidpervious, permitting liquids (e.g., menses, urine, and/or runny feces)to penetrate through its thickness. A topsheet 138 may be manufacturedfrom a wide range of materials such as woven and nonwoven materials;apertured or hydroformed thermoplastic films; apertured nonwovens,porous foams; reticulated foams; reticulated thermoplastic films; andthermoplastic scrims. Woven and nonwoven materials may comprise naturalfibers such as wood or cotton fibers; synthetic fibers such aspolyester, polypropylene, or polyethylene fibers; or combinationsthereof. If the topsheet 138 includes fibers, the fibers may bespunbond, carded, wet-laid, meltblown, hydroentangled, or otherwiseprocessed as is known in the art.

Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Aperturedfilm topsheets may be pervious to bodily exudates, yet substantiallynon-absorbent, and have a reduced tendency to allow fluids to pass backthrough and rewet the wearer's skin. Exemplary apertured films mayinclude those described in U.S. Pat. Nos. 5,628,097; 5,916,661;6,545,197; and 6,107,539.

As mentioned above, the pant diaper 100 may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2A, theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper 100. Exemplary absorbent structures for use as the absorbentcore of the present disclosure are described in U.S. Pat. Nos.4,610,678; 4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprises primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 and 2004/0097895.

As previously mentioned, the diapers 100 may also include elasticizedleg cuffs 156. It is to be appreciated that the leg cuffs 156 can be andare sometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115;4,909,803; and U.S. Patent Publication No. 20090312730A1.

As mentioned above, pant diapers may be manufactured and provided toconsumers in a configuration wherein the front waist region and the backwaist region are pre-fastened or connected to each other as packaged,prior to being applied to the wearer. For example, the pant diaper 100may be folded about a lateral centerline with the interior surface 132of the first waist region 116 in surface to surface contact with theinterior surface 132 of the second waist region 118. As such, pantdiapers may have a continuous perimeter waist opening and continuousperimeter leg openings designed for infant or adult wearers. Asdiscussed in more detail below, a diaper pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the diaper using refastenable and/or permanent closuremembers (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). In addition, pant diapers can bepreformed anywhere along the circumference of the waist region (e.g.,side fastened or connected, front waist fastened or connected, rearwaist fastened or connected).

As previously mentioned, pant diapers may be configured with side panelsconnected with the chassis in one or both of the waist regions. Forexample, the pant diaper 100 shown in FIGS. 1 and 2A includes first sidepanels 112 a, 112 b connected with second side panels 114 a, 114 b,respectively. The first side panels 112 a, 112 b are refastenablyconnected with the chassis 102 in the first waist region 116 and extendlaterally outward from the side edges 128, 130 of the chassis. Thesecond side panels 114 a, 114 b are permanently connected with thechassis 102 in the second waist region 118 and extend laterally outwardfrom the side edges 128, 130 of the chassis. As shown in FIG. 2A, thesecond side panels 114 a, 114 b are defined by opposing end regions of acontinuous belt 114 that is permanently connected with the chassis 102along the second waist region 118. The first side panel 112 a isconnected with the second side panel 114 a, and the first side panel 112b is connected with the second side panel 114 b. The first side panels112 a, 112 b each include proximal regions 174 a refastenably connectedwith the first waist region 116 of the chassis 102. And second earpanels 114 a, 114 b each include proximal regions 174 b defined by thecontinuous belt 114 permanently connected with the second waist region118 of the chassis 102. With reference to FIGS. 1 and 2A, a distalregion 176 a of the first side panel 112 a and a distal region 176 b ofthe second side panel 114 a may be connected with each other along afirst side seam 178. And a distal region 176 a of the first side panel112 b and a distal region 176 b of the second side panel 114 b may beconnected with each other along a second side seam 180.

It is to be appreciated that the second side panels may be configured indifferent ways other than as depicted in FIG. 2A. For example, FIG. 2Bshows a plan view of a pant diaper 100 having the same components asdescribed above with reference to FIG. 2A, except the second side panels114 a, 114 b shown in FIG. 2B are not defined by opposing end regions ofa continuous belt 114. Instead, the second side panels 114 a, 114 bshown in FIG. 2B are defined by two separate and discrete pieces ofmaterial connected with the second waist region 118 of the chassis 102.In particular, the second ear panels 114 a, 114 b each include proximalregions 174 b permanently connected with the second waist region 118 ofthe chassis 102.

The side panels 112 a, 112 b and 114 a, 114 b may be substantiallyrectangular in shape or the side panels may be shaped in such a way asto provide an integral tab for ease of opening and refastening. The sidepanels may also be extensible in at least the lateral direction. Theside panels may also be elastically extensible in the lateral direction.Furthermore, the side panels may be elastically extensible in both thelongitudinal and lateral directions. The side panels may comprise afilm, a nonwoven or a combination of film and nonwoven. The side panelsmay also comprise a plurality of strand-like filaments and a nonwoven.The strand-like elements may also be elastically extensible in at leastthe lateral direction.

It is to be appreciated that the side panels may include various typesof materials, such as disclosed with respect to the elastic beltsdescribed in U.S. Pat. No. 7,569,039, which is hereby incorporated byreference herein. For example, the side panels may include plasticfilms; apertured plastic films; nonwoven or nonwoven webs of naturalmaterials (e.g., wood or cotton fibers); synthetic fibers (e.g.polyolefins, polyamides, polyester, polyethylene, and/or polypropylenefibers); or combinations of natural and/or synthetic fibers; or coatedwoven or nonwoven webs. In some embodiment, the side panels may includea stretchable nonwoven. In other embodiments, the side panels mayinclude an inner hydrophobic non-stretchable nonwoven material and anouter hydrophobic, non-stretchable nonwoven material. In addition, theside panels may include waist elastic material and side elastic materialincluding one or more of elastic elements such as strand or panelsextending in a transverse direction. The side panel elastic material mayalso be interposed between an outer layer and inner layer.

The ability to refasten an initially pre-fastened pant diaper may offerconvenience to the caregiver. In some instances, it may be moreconvenient to apply the absorbent article like a traditional tape stylediaper when away from home or when it is inconvenient to remove theclothing and/or shoes. Because it is difficult to predict when a changewill be necessary and therefore when a particular mode of applicationwill be needed, it is beneficial to have a disposable pant diaper thatis adaptable to being applied either as a traditional tape style diaperor as a disposable pant diaper, pull-on. In addition, an absorbentarticle that can be applied like a traditional tape style diaper or adisposable pant diaper also permits inspection of the interior of theproduct without having to pull the product down. These refastenablestructures may also provide dual functionality enabling the wrapping anddisposal of the used product.

It is to be appreciated that the proximal regions of the side panels maybe connected with the chassis in various ways, and the distal regions ofthe ear panels may be connected with each other in various ways. Forexample, the proximal regions and/or distal regions of the side panelsdisposed in one or both of the waist regions may be permanently bonded,releasably connected, and/or refastenably connected with the chassisand/or each other, with for example, adhesives, cohesives, thermalbonding, ultrasonic bonding, mechanical bonding and mechanical fasteninge.g. hook and loop type fasteners. For example, one or more fastenerelements may be located on the side panels and may be adapted torefastenably connect with one or more corresponding fastening elementslocated in the first or second waist regions or alternatively thefastener elements may be adapted to refastenably connect with one ormore components of the absorbent article including the side panels. Thediaper pants can also include other features such as elasticallyextensible side panels that may each include one or more pieces ofmaterial.

It should also be appreciated that the side panels in one waist regionmay have the same lateral extent from the side edge of the chassis tothe distal edge of the side panel as the longitudinally opposed sidepanels in the opposite waist region or alternatively the side panelsdisposed in a first waist region may have different lateral extent asmeasured from the side edge of the chassis to the distal edge of theside panel than the side panels disposed in a second waist region. Aspreviously mentioned, the bonds of the side edge seams 178 and 180 maybe permanent and can be formed in various ways appropriate for thespecific materials employed. Thus, example bond types may includediscrete bonds such as sonic sealed bonds, heat sealed bonds, highpressure bonds, radio frequency bonds, adhesive or cohesive bonds, sewedbonds, autogeneous bonds, and combinations thereof. In accordance withone aspect of the disclosure, the permanent side edge seams 178 and 180may be joined by a predetermined pattern of heat/pressure or ultrasonicwelds which withstands the forces and stresses exacted onto the sideedge seam during application and wear of the pant. The permanent sideedge seams 178, 180 may be formed as disclosed in U.S. Pat. Nos.5,779,831; 5,772,825; 5,607,537; 5,622,589; 5,662,638; 6,042,673; and6,726,792.

As mentioned above, the first side panels 112 a, 112 b may berefastenably connected with the first waist region 116 of the chassis102. As such, the first side panels 112 a, 112 b may be configured toinclude fastening components 162, such as shown in FIG. 2A. Thefastening components 162 may form a portion of or may be permanentlybonded, adhered or otherwise joined directly or indirectly to the firstside panels 112 a, 112 b at or adjacent the proximal edge regions 174 aof the first side panels 112 a, 112 b. In some embodiments, thefastening components 162 may be permanently bonded to the first sidepanels 112 a, 112 b in various ways, such as for example, by adhesivebonds, sonic bonds, pressure bonds, thermal bonds or combinationsthereof.

The fastening components 162 are adapted to refastenably connect withthe first waist region 116 of the chassis 102. As such, the fasteningcomponents 162 may include various types of refastenably engageablefasteners and various types of refastenable fastening structures. Forexample, the fastening components 162 may include mechanical fasteners,166, in the form of hook and loop fasteners, hook and hook fasteners,macrofasteners, buttons, snaps, tab and slot fasteners, tape fasteners,adhesive fasteners, cohesive fasteners, magnetic fasteners,hermaphrodidic fasteners, and the like. Some examples of fasteningsystems and/or fastening components 162, 164 are discussed in U.S. Pat.Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092;5,221,274; 6,251,097; 6,669,618; 6,432,098; and U.S. Patent PublicationNos. 2007/0078427 and 2007/0093769.

As previously mentioned, the fastening components 162 may be adapted torefastenably engage or connect with another portion of the diaper 100.For example, as shown in FIG. 2A, the diaper 100 may include aconnection zone 168, sometimes referred to as a landing zone, in thefirst waist region 116. As such, when the taped diaper 100 is placed ona wearer, the fasteners 162 are refastenably connected with theconnection zone 168 in the first waist region 116 to form a closed waistcircumference and a pair of laterally opposing leg openings. It is to beappreciated that the connection zone 162 may be constructed from aseparate substrate that is connected with the chassis 102 of the tapeddiaper. In some embodiments, the connection zone may be integrallyformed as part of the backsheet 136 of the diaper 100 or may be formedas part of the first and second ears in one or both of the waistregions, such as described in U.S. Pat. Nos. 5,735,840 and 5,928,212. Aspreviously mentioned, the apparatuses and methods according to thepresent disclosure may be utilized to assemble various components ofpre-fastened, refastenable pant diapers 100. For example, FIG. 3 shows aschematic view of a converting apparatus 300 adapted to manufacture pantdiapers 100. The method of operation of the converting apparatus 300 maydescribed with reference to the various components of pant diapers 100described above and shown in FIGS. 1 and 2A.

As described in more detail below, the converting apparatus 300 shown inFIG. 3 operates to advance discrete chassis 102 along a machinedirection MD such that the lateral axis of each chassis 102 is parallelwith the machine direction, and wherein the chassis 102 are spaced apartfrom each other along the machine direction. In addition, the apparatus300 refastenably connects the front side panels 112 a, 112 b with firstwaist regions 116 of advancing chassis 102 and permanently connects theback side panels 114 a, 114 b with the back waist regions 118 ofadvancing chassis 102.

As shown in FIGS. 3 and 5A, a continuous length of chassis assemblies302 are advanced in a machine direction MD to a carrier apparatus 308and cut into discrete chassis 102 with knife roll 306. The continuouslength of chassis assemblies may include absorbent assemblies 140sandwiched between topsheet material 138 and backsheet material 136, legelastics, barrier leg cuffs and the like. A portion of the chassisassembly is cut-away to show a portion of the topsheet material 138 andan absorbent assembly 140. The continuous length of chassis assemblies302 may also include connection zones 168 connected with the backsheetmaterial 136 and spaced apart from each other along the machinedirection MD.

After the discrete absorbent chassis 102 are cut by the knife roll 306,the carrier apparatus 308 rotates and advances the discrete chassis 102in the machine direction MD in the orientation shown in FIG. 5B1,wherein the longitudinal axis 124 of the chassis 102 is generallyparallel with the machine direction MD. While the chassis 102 shown inFIG. 5B1 is shown with the first laterally extending end edge 144 as aleading edge and the second laterally extending end edge 146 as thetrailing edge, it is to be appreciated that in other embodiments, thechassis 102 may be advanced in other orientations. For example, thechassis may be oriented such that the first laterally extending end edge144 is a trailing edge and the second laterally extending end edge 146is a leading edge. The carrier apparatus 308 also rotates while at thesame time changing the orientation of the advancing chassis 102. Thecarrier apparatus 308 may also change the speed at which the chassis 102advances in the machine direction MD. It is to be appreciated thatvarious forms of carrier apparatuses may be used with the methodsherein, such as for example, the carrier apparatuses disclosed in U.S.Pat. No. 7,587,966. FIG. 5B2 shows the orientation of the chassis 102 onthe carrier apparatus 308 while advancing in the machine direction. Moreparticularly, FIG. 5B2 shows the chassis 102 with the lateral axis 126of the chassis 102 generally parallel with the machine direction MD, andwherein the first longitudinal side edge 128 as the trailing edge andthe second longitudinal side edge 130 as the leading edge. As discussedbelow with reference to FIGS. 3, 5C, 5D, 5E, 5F1, 5G, and 5H, thechassis 102 are transferred from the carrier apparatus 308 and combinedwith materials that form first side panels 112 a, 112 b and second sidepanels 114 a, 114 b.

With reference to FIGS. 3 and 5C, the chassis 102 are transferred fromthe carrier apparatus 308 to a nip 316 between the carrier apparatus 308and a carrier apparatus 318 where the chassis 102 is combined with acontinuous length of advancing back side panel material 310. The backside panel material 310 defines a wearer facing surface 312 and anopposing garment facing surface 314. And the wear facing surface 312 ofthe back side panel material 310 may be combined with the garment facingsurface 134 of the chassis 102 along the second waist region 116. Asshown in FIG. 3, adhesive 320 may be intermittently applied to thewearer facing surface 312 before combining the back side panel material310 with the discrete chassis 102.

As shown in FIGS. 3, 5D, and 5E, a continuous length of front side panelmaterial 322 advances in a machine direction MD to carrier apparatus318, where a knife roll 324 cuts the continuous length of front sidepanel material 322 into discrete lengths of front side panel material322 a. As shown in FIG. 3, the discrete lengths of front panel material322 a are spaced from each other in the machine direction by the carrierapparatus 318. An example carrier apparatus 318 for achieving thespacing between discrete components is disclosed in disclosed in U.S.Pat. No. 7,587,966.

With continued reference to FIGS. 3 and 5D, the front side panelmaterial 322 also defines a wearer facing surface 326 and an opposinggarment facing surface 328. And fastening components 162 areintermittently spaced along the machine direction MD on the wearerfacing surface 326 of the front side panel material 322. As shown inFIG. 5D, the fastening components 162 are arranged in pairs 330 offastening components 162 in close proximity to each other, and the pairs330 are spaced apart from other pairs 330 along the machine directionMD. With reference to FIGS. 3 and 5E, the knife 324 cuts the front sidepanel material 322 at locations between the two fastening components 162of each pair 330, thus creating discrete lengths or patches of frontside panel material 322 a. As shown in FIG. 5E, fastening components 162are located in opposing end portions each discrete length or patch offront side panel material 322 a. As such, the discrete length of frontside panel material 322 a includes a leading end fastening component162′ and a trailing end fastening component 162″. As shown in FIG. 3,the anvil roll 318 advances the discrete lengths of front side panelmaterial 322 a to the nip 316, where each discrete length of front sidepanel material 322 a is connected with two chassis 102. Moreparticularly, the leading end fastening component 162′ is refastenablyconnected with the connection zone 168 in the first waist region 116 ofa chassis 102 being transferred from the carrier apparatus 308 at thenip 316. And the trailing end fastening component 162″ is refastenablyconnected with the connection zone 168 of a chassis 102 subsequentlytransferred from the carrier apparatus 308 at the nip 316. As such,opposing end portions of each discrete length of front side panelmaterial 322 a are refastenably connected with two chassis 102 travelingin the machine direction, such as shown in FIG. 5F1.

With reference to FIGS. 3 and 5F1, multiple discrete chassis 102 spacedfrom each other along the machine direction MD are connected with eachother by the back side panel material 310 and discrete lengths of frontside panel material 322 a. And the chassis 102 are advanced from the nip316 to a folder 332. Various folder embodiments may be used, such as forexample disclosed in U.S. Pat. No. 6,913,664, which is incorporated byreference herein. At the folder 332, each chassis 102 is folded in thecross direction CD along a lateral axis 126 to place the first waistregion 116, and specifically, the inner, body facing surface 132 into afacing, surface to surface orientation with the inner, body surface 132of the second waist region 118. The folding of the chassis alsopositions the wearer facing surface 312 of the back side panel material310 extending between each chassis 102 in a facing relationship with thewearer facing surface 326 of the front side panel material 322 aextending between each chassis 102. As shown in FIGS. 3 and 5G, thediscrete chassis 102 connected with the back side panel material 310 anddiscrete lengths of front side panel material 322 a are advanced fromthe folder 332 to a bonder 334. The bonder 334 operates to bond aportion of the back side panel material 310 extending between eachchassis 102 with a portion of the front side panel material 322 aextending between each chassis 102, thus creating discrete bond regions336. It is to be appreciated that various types of bonders can be usedto bond the back side panel material 310 with the front side panelmaterial 322 a, such as for example disclosed in U.S. Pat. Nos.7,383,865 and 6,546,987, which are incorporated by reference herein.

As shown in FIGS. 3 and 5H, the discrete chassis 102 connected with thecontinuous back side panel material 310 and discrete lengths of frontside panel material 322 a are advanced from the bonder 334 to a kniferoll 338 where the discrete bond regions 336 are cut into along thecross direction to create a first side seam 178 on an absorbent article100 and a second side seam 180 on a subsequently advancing absorbentarticle.

FIG. 4 shows a schematic view of a second embodiment of a convertingapparatus 300′ adapted to manufacture pant diapers 100, such as shown inFIG. 2B. As discussed in more detail below, the method of operation ofthe converting apparatus 300′ differs from the converting apparatusdescribed above with respect to FIG. 3 with respect to the connection oftwo separate and discrete second ear panels 114 a, 114 b with the secondwaist region 118 of the chassis 102. Other aspects of the assemblyprocess shown in FIG. 4 are the same as described above with referenceto FIGS. 3, 5A, 5B1, 5B2, 5D, 5E, 5G, and 5H.

With reference to FIGS. 4 and 5J, a continuous length of back side panelmaterial 310 defining a wearer facing surface 312 and an opposinggarment facing surface 314 advances in a machine direction MD to acarrier apparatus 340. At carrier apparatus 340, a knife roll 342 cutsthe continuous length of back side panel material 310 into discretelengths of back side panel material 310 a. As shown in FIG. 5K, eachdiscrete length of back side panel material 310 a includes a leading endportion 344 a and a trailing end portion 344 b. As shown in FIG. 3, thediscrete lengths of back panel material 310 a are spaced from each otherin the machine direction by the carrier apparatus 340. An examplecarrier apparatus 340 for achieving the spacing between discretecomponents is disclosed in disclosed in U.S. Pat. No. 7,587,966. Asshown in FIG. 3, adhesive 346 may be intermittently applied to thewearer facing surface 312 before combining the back side panel material310 a with the discrete chassis 102.

After applying adhesive, the wearer facing surface 312 of the back sidepanel material 310 a may be connected with the garment facing surface134 of the chassis 102 along the second waist region 116 at nip 316.More particularly, each discrete length of back side panel material 310a is connected with two chassis 102, wherein the leading end portion 346a is bonded with the second waist region 116 of a chassis 102 beingtransferred from the carrier apparatus 308 at the nip 316 and thetrailing end portion 346 b is bonded with the second waist region ofanother chassis 102 subsequently transferred from the carrier apparatus308 at the nip 316. As such, opposing end portions of each discretelength of back side panel material 310 a are bonded with two chassis 102traveling in the machine direction, such as shown in FIG. 5F2. And theleading end portions 344 a and the trailing end portions 344 b of theback side panel material 310 a correspond with the proximal regions 174b the second ear panels 114 a, 114 b discussed above with reference toFIG. 2B. From the nip 316, the discrete chassis connected with eachother by the discrete lengths of back side panel material 310 a anddiscrete lengths of front side panel material 322 a are advanced fromthe nip 316 to folder 332, bonder 334, and knife roll 338 as discussedabove with reference to FIGS. 5F1, 5G, and 5H.

Although the processes and apparatuses have been described in thecontext of assembling absorbent articles having side panels refastenablyconnected with the first waist region, it is to be appreciated that theprocesses and apparatuses described above can be configured to assembleabsorbent articles having various other configurations. For example, theabove described processes and apparatuses can be configured to assembleabsorbent articles with side panels refastenably connected with thesecond waist region. In another example, the above described processesand apparatuses can be configured to assemble absorbent articles withfour side panels refastenably connected to both the first and secondwaist regions, and wherein the corresponding side panels are bondedtogether along side seams.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process for assembling disposable pre-fastenedpant diapers, each pant diaper comprising a chassis having a first waistregion longitudinally opposed to a second waist region, and having alongitudinal axis and a lateral axis, the chassis comprising: atopsheet, a backsheet, and an absorbent core disposed between thetopsheet and the backsheet, each pant diaper further comprisinglaterally opposed first side panels refastenably connected with thefirst waist region; and laterally opposed second side panels permanentlyconnected with the second waist region and permanently connected withcorresponding first side panels to form a waist opening, the processcomprising the steps of: advancing a first continuous web having a firstsurface and an opposing second surface in a machine direction whereinfastener components are connected with the first surface; cutting thefirst continuous web into discrete patches, each patch having a leadingend region, a trailing end region, and a central region disposed betweenthe leading and trailing end regions, wherein a first fastener islocated in the leading end region and a second fastener is located inthe trailing end region; advancing a second continuous web in themachine direction; advancing a third continuous web in the machinedirection; cutting the third continuous web into discrete chassis,wherein each chassis advances such that the longitudinal axis isparallel with the machine direction; turning each chassis such that thelateral axis is parallel with the machine direction; refastenablyconnecting the first waist region of each chassis with a trailing endregion of a first advancing patch and with a leading end region of asecond advancing patch; permanently connecting the second waist regionof each chassis with the second continuous web; folding each chassisalong the lateral axis to position the central region of each patch intoa facing relationship with the second continuous web; bonding a portionof the central region each patch with the second continuous web tocreate discrete bond regions; and cutting the second continuous web andthe patches along the bond regions to create discrete pre-fastenedrefastenable pant diapers.
 2. The process of claim 1, wherein the firstwaist region is a front waist region.
 3. The process of claim 1, whereinthe second waist region is a back waist region.
 4. The process of claim1, wherein the first continuous web comprises a continuous length offront side panel material.
 5. The process of claim 1, wherein thepatches comprise discrete lengths of front side panel material.
 6. Theprocess of claim 1, wherein the second continuous web comprises acontinuous length of back side panel material.
 7. The process of claim1, wherein the third continuous web comprises a continuous length ofchassis assemblies.